Welding control system with polarizing relay



March 28, 1939. J. w. DAWSON 2,151,749

WELDING CONTROL SYSTEM WITH POLARIZING 'RELAY Filed Nov. 6, 1937 '2 Sheets-Sheet l NESSES: INVENTOR I a70/772 WDawson.

ATTORNEY Max-ch28, 1939. J. w. DAWSON 2,151,749

WELDING CONTROL SYSTEM WITH POLARIZING RELAY Filed Nov. 6, 1937 2 Sheets-Sheet 2 BY lv I ATTORNEY ESESz 30/ INVENTOR Job/7 WDczwsazz.

Patented Man-28, 1939 UNITED STATES PATENT OFFICE WELDING CONTROL SYSTEM WITH POLARIZING RELAY of Pennsylvania Application November 6, 1937, Serial No. 173,182

Claims.

My invention relates to means for controlling the application of a predetermined number of half cycles of alternating current to a load circuit, and especially to such application toa welding circuit.

An object of my invention is to prevent saturization of transformers in the load circuit where an odd number of half cycles is periodically applied thereto.

" It often happens in the application of a predetermined number of half cycles to a load circuit, such as a welding circuit, that an odd number of half cycles is applied thereto periodically. If these half cycles should, for example, be positive, negative and positive and then repeated with the same sign at necessary intervals, there would be applied to the circuit a preponderance of positive half cycles that would saturate the transformer which is present in these load circuits of the welding type. According to my invention, I provide means to prevent the saturation by ensuring that the weld will start on the helf cycle difierent in sign from the last half cycle upon .which the prior weld was completed. By this 0 means, at the end of any predetermined number of welds utilizing an odd number of half cycles, the load circuit has, at the most, only one more half cycle of one sign applied thereto than the number of half cycles of the opposite sign,

Other objects and advantages of the invention will be apparent from the following description and drawings in which:

Figure 1 is a diagrammatic circuit disclosing a preferred embodiment of my invention applied 35 to a loading circuit;

Fig. 2 is a top plan view; and I Fig. 3 is a view in side elevation of a preferred type of relay utilized in my invention. Ihave illustrated the application of my invention to a welding circuit in Fig. 1.

Referring to the figures of the drawings, the reference character It) designates generally a welding transformer having a primary winding I I and a secondary winding l2. The secondary winding I2 is connected to the. customary welding circuit in which the welding electrodes l3, I4 are diagrammatically represented applied to objects I 5 which are to be welded together. The primary winding ll of the transformer is connected by 0 means ofconductors I6 and I|.to a source of alternating current.

I In order to control the application of the welding current from the source of alternating current to the transformer l0, vapor electric del vices shown generally at 18 and I9 are provided.

The devices l8 and I9 are of the mercury vapor type having an anode and a mercury pool 2| as a cathode in the bottom of a container 22. In order to render the vapor electric devices l8 and I9 conducting, a starting electrode 23 is provided.

Although other types of starting electrodes may be utilized, I prefer to use a high resistance electrode immersed in the mercury and composed of carborundum or boron carbide. This type of starting electrode is well known in the art and is more specifically described in Patent 2,069,283, issued February 2, 1937, to Slepian.

The two devices 16 and I9 are disclosed in order that both directions of the alternating current may be controlled in theapplication to the welding circuit, since each device acts as a rectifier as well as being a controllable conductor.

When a. certain amount of current is caused to flow through the starting electrode 23 into the mercury pool 2|, a cathode spot is formed which furnishes a source of electrons which, in turn, causes ionization of the mercury vapor within the container 2|, and under the influence of positive anode potential, the tube becomes conducting. Thus, it is only necessary to pass sufflcient starting current through the starting or ignition electrode 23 to form the cathode spot at a predetermined time in the proper half cycle in the alternating-current wave to render the vapor electric devices conducting for the remainder of that particular half cycle. In order to conduct succeeding half cycles of alternating current, the vapor electric devices l8 and 19 are connected inversely. That is, the anode 20 of device 18 is connected to the cathode 2| of device l9 and the anode 20 of device I9 is connected to the cathode 2| of device l8. It will, therefore, be evident that if the vapor electric devices l8 and I9 are energized in turn during successive half cycles, current 40 from the source of alternating current will flow to the transformer I0 as long as this condition is maintained.

The control system which I prefer'to utilize is that described in my copending application for Welding timing circuits, Serial No. 142,564, filed May 14, 1937. It is obvious, however,- that my invention is also applicable to the control systems different from that described in this copending application.

The controlsystem, as described in this copending application, involves the utilization of control tubes for supplying ignition current to control the discharge in the tubes 18 and I9 and also electronic devices for accurately operating tion of this control system is preferably instituted by an externally operated switch 29 which may be operated manually or by a cam on the welding machine. In other words, when the operator desires to perform the welding operation, he dethe switch 28, energizing the relay 38 from the conductors 3|, 32 connected to the source of alternating current. The relay 38, in turn, operates various individual switches hereinafter referred to in the description of the control circuit.

The cathodes of the tubes 24 and 25 are energized from the alternating circuit by transformers 83 and 84, respectively. The midpoint of the secondary of the transformer 33, namely 35, has a connection 88 extending tothe starting electrode 28 of tube I8. Likewise, the midpoint 88 of the secondary of transformer 34 is connected through connection 38 to the starting electrode 23 of the tube I8. The anode 4| of tube 24 is connected through resistance 31 and switch point 42 of the starting relay 38 to the connection 43 to the anode 28 of tube I8. The anode 44 of tube 25 is likewise connected through resistance 48 and switch 45 of the relay 88 to the connection 48 to the anode 28 of tube I8. The grids 41 and 48 of tubes 24 and 25 are connected through suitable resistances 48 and 58 to opposite ends of the secondary 5| of transformer 52 connected to the source of alternating current. The grids and cathodes of tubes 24 and 25-may be energized from secondary windings on the same transformer instead of the individual transformers disclosed. Between the conductors 48 and 48 extending to thecathodes and anodes of the tubes I8 and I8 previously described is a resistance 53. The variable tap 54 on this resistor is to compensate for .any slight difference between the tubes I8 and current potential which would otherwise exist on the grids 41 and 48 of tubes 24 and 25 because of their circuit locations.

Tube 28 is utilized as a' starting device. Its cathode 88 is energized through the transformer of secondary 8| of transformer 82 and the midpoint 83 of this secondary is connected through resistance 85, its midpoint 84 and connections 88 to the midpoint 81 of the transformer secondary 5I connected to the grids 41 and 48 of the tubes 24 and 25. The anode 88 of tube 28 is connected to the positive terminal 88 of a source of directcurrent potential disclosed as the rectifier grid 18 connected to a transformer 1| energized from the source of alternating current. The negative terminal 12 is connected through conductor 13 to the resistance 85, cathode transformer secondary 8| and cathode 88. The grid 14 of. tube 28 is connected through a connection to the negative terminal 18 of a similar rectifier bridge 11 also energized by the alternating-current source. These rectifier bridges are preferably of the wellknown copper-oxide dry plate type. The negative potential from the rectifier bridge 11 on the grid 14 constitutes a discharge preventing bias normally applied to the control electrode of the starting tube 28.

The operation of the starting tube 28 is controlled by means of the timing tube 28 previously referred to which controls the point of initiation of tube 28 with respect to the voltage wave. This timing tube 28 is preferably of the hot-cathode gaseous discharge type and is provided with a phase-shifting control circuit 88 for the grid 8| of the tube. This phase-shifting control circuit comprises an adjustable resistor 82 and an adjustable capacitor 83. The phase-shifting circuit 88 is connected by means of a transformer 84 to the same source of alternating'current as is applied to the anode '85 and cathode 88 of the timing tube 28. Alternating current for the timing tube 28 is provided from windings on the secondary of transformer 84. The output of timing tube 28 is applied to a circuit comprising the resistor 81 and a winding 88 of a transformer 89. The secondary winding 88 of the transformer 88 is indirectly connected to the grid 14 of the starting tube 28 when the switch I28 of relay 38 is closed through the connection 15 which, as previously described, normally applies a negative d1..- charge preventing potential to this grid 14.

The phase-shifting circuit 88 is adjusted by means of the variable resistor 82 and variable capacitor 83 to render the start tube 26 conducting at the desired point in the cycle of operation of the alternating-current source. The phaseshifting circuit 88 will determine the exact point on the voltage wave that the tube 28 will be rendered conducting. The discharge in tube 28 permits current to fiow through the primary winding 88 of transformer 88, and due to the steep wave front of the current applied, a sharp voltage surge will appear in the secondary winding 98 which will be applied, in turn, to the grid 14 of the starting tube 28. The peak value of the surge is sufllcient to overcome the negative potential of the source 11 and to positively bias the grid 14, thereby rendering the start tube 28 conducting. As soon as the start tube 28 becomes conducting, a positive potential is applied to the control tubes 24 and and they will then function to establish the conductivity of tubes I8 and I9.

It will be noted that the cut-off space discharge device 21 has its anode I88 connected through switch IIII to the same positive terminal of the rectifier bridge 18 as the anode 88 of the starting tube 28. The cathode I82 of the cut-off tube 21 is connected through the midpoint I83 of the transformer secondary I84 by means of a connection I85 to the midpoint 54 of the resistance 53 across the anodes and cathodes of the tubes I 8 and I 8. The grid I88 of cut-ofl tube 21 is connected through adjustable resistance I81 to the cathode 88 of the starting tube 28, an adjustable timing condenser I 88 is connected to the cathode circuit 83, cathode 88 of the starting tube 28 and conductor 13 extending from the negative terminal of the direct-current rectifier bridge 18 to the'resistance 85. The resistance or voltage divider I89 extends from the connection 88 between the anodes of tubes 28 and 21 to the point II8 on the conductor 13 connected to the grid I88 of tube 21. A tap I I I is taken from a point on the potentiometer and by means of connection H2 is applied to the cathode 182 of the cut-oil tube 21. It will be noted that the point 8 with respect to III corresponds to the negative grid potential 2,151,749 -of the cut-oil tube 21. The point III corre-- sponds to the cathode potential of the tube 21.

The conduction of the tube 26 will apply potential across the resistor and this potential acts to charge the condenser I08 through the variable resistance I01. After a time variable between adjustment of resistor I01, condenser I08 is sufflciently charged to raise the grid I06 of tube 21 to its breakdown point with respect to its cathode I02. With the breakdown of this tube positive, potential is fed through the tube' and its cathode transformer to wire I05 which action again throws the bias on control tubes 24 and 25 to a negative value, stopping the further ignition of the tubes I8 and I9 and hence further welding currents after the termination of the particular half-cycle. Leads 66 and I05 are the timing circuit output leads.

When neither tube 20 nor 21 is ignited, the lead 66 is negative to lead I05. When the starting tube 26 discharges, the lead 66 becomes positive and th: lead I05 becomes negative. When I the stop tube ignites, the lead 66 again becomes negative in respect to the lead I05. During the period while lead 66 is positivein respect to lead I05, welding current can flow.

The weld has, accordingly, been completed by the automatic operation of tubes accurately timing the predetermined number of half cycles of alternating current. No manual operation by the operator in connection with the control circuit is necessary after the work I5 is in position, except for the depression of the manual switch 29.

' The sequence of the switches operated thereby is first, switch IOI to energize rectiflers 10 and 11, then switches 45 and 42 together and then switch I20. After the weld has been completed, the pressure is released from switch 29 and the various switches operated by relay 30 will be released in reversed order, namely, switches I20, 42 and 45 and then switch I0 I, but the connection-at switch I I5 will be made to discharge the timing condenser I08 and have it ready for the next operation.

It will be noted that both the negative component of the timing voltage applied to tube 21, i. e., between points I I0 and I I I, and the positive component of timing voltage, i. e., the voltage across condenser I08, are derived from the same source 10, and, accordingly, variations in this source due to changing of temperature or other causes will equally effect the positive and negative components of grid voltage as applied to tube 21, and will not change, therefore, the accuracy of timing following the discharge of tube 26.

Various condensers and resistances are, of course, illustrated at desired places in the apparatus, some of which, as at H6 and H1, acting as filters.

My invention contemplates reversing when necessary the application of the secondary coil 84 to the tube 28, which tube determines the starting point of the application of the welding power at the predetermined point of the initial half cycle. This reversing means I have disclosed as a relay 200 which preferably has a permanent magnet 20I with an air gap 202 inserted between two of its extended arms or legs. A coil 203 is placed about one of the legs 204 of the magnet and another coil 205 is placed around the other leg 20B of the magnet. These coils are connected in series and are connected by conductors 201 and 208 to be associated with the main welding power circuit feeding the welding transformer I0. This association may take the form of the direct connection to the alternating-current mains as disclosed, with a suitable resistance 209 thereacross, or may take' place with a current transformer or any other suitable means, as desired.

An armature 2I0 plays back and forth in the 5 air-gap 202 between the faces 2 and H2 of the permanent magnet in responset'o the influence of the magnetization of the coils 203 and 205 about the legs of the magnet. A direct-current coil 2I3 is placed about this armature and is fed with suit- 10 able direct. current from a source 2 I4 to maintain a constant polarity of the armature. The armature has a connection 2 I 5 extending to the anodes 85 of tube 28 and another connection 2I6 extending to the grid circuit of tube 28. These two con- 15 nections are, of course, insulated from each other by insulation 2 I 1 on the armature.

The contact 2I8 alternately connects the anode connection 2I5 to the contact 2| 9 attached to the upper end of coil 84 and then to contact 220 con- .20

nected to the lower end of coil 84. The contact 2 2I on the armature having electrical connection with conductor 2I6 connected to the grid 8| of the tube 28, is alternately connected to contact 222 connected to the lower end of coil 84 and then to 28 contact 223 connected to the upper end of coil 84.

This relay is disclosed with the armature pivoted at 224.

In Figs.'2 and 3 are disclosed actual elevational views of a preferred type of device to utilize for 80,

the relay. The permanent magnet circuit is designated with a base 20I' and arms 204 and 206' having extensions forming air-gaps 202'. The coils 203 and 205' are placed about these arms.

and the direct-current coil 2|3 is also disclosed.

The armature preferably is composed of two members 230 and 23I pivoted one on the other at 232 in a toggle arrangement. The lower member 230 is preferably pivoted by a knife edge into a fixed groove at 233. The upper member 23I of the armature is held on a spring member 234 having turned-over edges holding a block 246 with a V-shaped notch therein for the upper pointed edge of armature 23!. The tension on armature 23I is regulated by the spring and nut assembly 235. Attached to the lower part of the armature 23I there is a bar 236 which, in turn, supports the contact members 243 and 244. Flexible leads 231 and 238 from terminals 241 and 248 extend to terminals 249 and 250 extending to contacts 243 and 244. These flexible leads 231 and 238 correspond to the flexible leads disclosed at 2I5 and 2IB in Fig. 1.

The contacts 2I9 and 220 in Fig. 1 are preferably constructed as spring members 239 and 240 disclosed in Fig. 3 having contact faces 24I and 242. Attached to the armature 23I is a contact face 243 to make contact with contact MI and another contact 244 to make contact with contact 242.

A duplicate set of these spring members and contacts at the opposite or back part of the relay constitutes the contacts 22 I, 222 and 223 disclosed in Fig. l. The adjustment of the spring and nut member 235 will ensure the positive connection between the armature and the contact faces on the spring members 239 and 240.

The operation of the device is as follows: It will be assumed that the connections are such that when the armature 2I0 in Fig. 1 makes contact with contacts 2 I 9 and 222, the cycle will start on a positive half cycle, and when the armature is in contact with contacts 220 and 223 the weld starts with a negative half cycle. The coils 203 and 205 about the relay are such'that when the r -weld ends on a positive half cycle, the pole of the armature 2| 0 in the airgap 202 is north and the pole iace H2 is a south pole. The direct-current coil 2|! is also arranged so that the armature is a south pole in the airgap 202.

We assume that the load has been applied for an odd number of half cycles and has started on a positive half cycle. This means, of course, that the weld ends on a positive half cycle and the pole 2 is a north pole. During the operation oi the weld, the positive and negative half cycles have succeeded one another too rapidly to move the armature. When the weld ends, however, the north pole of 2 will attract the south pole of the armature and the armature will be pulled into the position disclosed in Fig. 1 to the contacts 220 and 223. There will be an oil? interval and then with the contacts on 220 and 223, the next weld will start on a negative halt cycle because the connections to the tube 28 are such that the weld will start on the negative half cycle with these contacts as previously stated. The weld will end on a negative hali cycle because the timing mechanism has been set for an odd number of half cycles and the pole piece 2 will become a south pole when the weld ends negative, and this south pole will repel the south pole of the armature so that the armature will be repelled when the weld ends and the armature will also be attracted by north pole 212 into contact with contacts H9 and 222 during the rest interval. When the timing mechanism is actuated again, it will start the weld on a positive halt cycle because of this new position of the armature. Accordingly, during these three welds the start and stop of the weld has been first a positive half cycle, then a negative, and.then a positive halt cycle. The next weld, of course, would start on a negative hall cycle and end on a negative half cycle. According to my invention, this arrangement prevents a preponderance of half cycles of one sign or the other, and there will be no saturization of the transformer ID or any other similar eilfect in the load circuit.

In case the timing mechanism is set for an evennumber oi hall. cycles, the armature will re main in one position during both the interval and during the weld itself. My invention thus does not have to be disturbed in any way when an even number of half cycles is utilized.

The direct-current source 2 for the directcurrent coil 2| 3 may, instead of the battery disclosed, be derived from one of the rectifier bridges, such as III or 11. This construction has the advantage that the direct current will be interrupted during the oil interval and electrical energy conserved.

1. In combination, a load circuit and an altera predetermined number oi'hali cycles from said supply circuit in successive intervals to the load circuit, an electric discharge device determining the time of conductive connection 01 the supply circuit to said load circuit, a control circuit for said device connected to said supply circuit, and means connected to the load circuit side of said device for reversing the polarity of the lastmentioned connections to initiate the application of a load current in each said interval at a hall. cycle of opposite sign to the final hall cycle of the preceding interval.

3. In combination a load circuit and an alternating-current supply circuit, means applying a predetermined number of half cycles from said supply circuit in successive intervals to the load circuit, control lneans connected to said supply circuit for predetermining the time of initiation of the application of the supply current to the load circuit and means for reversing the connections of said control means to said supply circuit for making the initial half cycle of one interval of different sign than the final half cycle of the preceding interval.

4. In combination, a load circuit and an alternating-current supply circuit, means applying a predetermined number of half cycles from said supply circuit in successive intervals to the load circuit, means predetermining the initiation of the application of the supply current to the load circuit and electrical means including a reversing switch connected to said last-mentioned means and actuated by said load circuit for making the initial half cycleof one interval of different sign than the final half cycle of the preceding interval.

5. In combination, a load circuit and an alternating-current supply circuit, means applying a predetermined number of half cycles from said supply circuit in successive intervals to the load circuit, means predetermining the initiation of the application of the supply current to the load circuit and electrical means connected to said last-mentioned means and actuated by said load circuit for making the initial half cycle oi one interval of different sign than the final half cycle of the preceding interval including a reversing switch comprising a permanent magnet having two legs forming opposite poles across an air gap, coils on said legs connected to said alternating supply circuit, a magnetizable armature having a fixed pole in said air gap and reversing contacts actuated by said armature, said contacts being connected to the means determining the initiation and application of the half cycles to the load circuit.

JOHN W. DAWSON. 

